Fibrous substrate with a solid hypohalite precipitate formed therein

Abstract

A cleaning substrate which comprises at least one layer of a solid hypohalite precipitate, wherein the hypohalite precipitate is formed in situ on the layer of substrate material. A process for making a fibrous cleaning substrate comprising the steps of: a) providing at least one layer of fibrous material; b) exposing the fibrous layer to an aqueous alkaline earth salt solution; c) treating the fibrous layer with a hypochlorite solution; d) allowing the aqueous alkaline earth salt solution combine with the hypochlorite solution to form a solid hypochlorite precipitate around the fibers in the fibrous material and a liquid phase, and e) removing at least 65% of the liquid phase from the fibrous substrate.

1. A hypochlorite-releasing substrate comprising:
 a) at least one fibrous layer comprising fibers selected from the group consisting of: natural cellulose, regenerated cellulose, polyester, acrylic, nytril, cellulose ester, olefin, vinyl and mixtures thereof; 
 b) a solid hypochlorite precipitate, which is not in the form of particulates and which is formed around the fibers and in the interstices of the fibrous layer, is selected from the group consisting of: hypochlorite monohydrate salt, hypochlorite dihydrate salt, hemibasic hypochlorite salt, monobasic hypochlorite salt, dibasic hypochlorite salt, anhydrous hypochlorite salt, and mixtures thereof; wherein the at least one fibrous layer which contains the hypochlorite precipitate is free of any glues, binders, or adhesives; and 
 wherein the solid hypochlorite precipitate is evenly distributed in the at least one fibrous layer. 
 
     
     
       2. The hypochlorite-releasing substrate according to  claim 1 , wherein the solid hypochlorite precipitate is crystalline. 
     
     
       3. The hypochlorite-releasing substrate according to  claim 2 , wherein the solid hypochlorite precipitate contains up to 35% by weight of water. 
     
     
       4. The hypochlorite-releasing substrate according to  claim 2 , wherein the solid hypochlorite precipitate contains up to 25% by weight of water. 
     
     
       5. The hypochlorite-releasing substrate according to  claim 1 , wherein the solid hypochlorite precipitate is amorphous. 
     
     
       6. The hypochlorite-releasing substrate according to  claim 5 , wherein the solid hypochlorite precipitate contains up to 40% by weight of water. 
     
     
       7. The hypochlorite-releasing substrate according to  claim 5 , wherein the solid hypochlorite precipitate contains up to 30% by weight of water. 
     
     
       8. The hypochlorite-releasing substrate according to  claim 1 , wherein the fibers are selected from the group consisting of: polypropylene, polyethylene, polyester and any mixtures or combinations thereof. 
     
     
       9. The hypochlorite-releasing substrate according to  claim 1 , wherein the fibrous material is a non-woven material selected from the group consisting of: spunbond, meltblown, spunbond meltblown spunbond, carded, wetlaid, airlaid, thermalbonded, hydroentangled, through-air bonded, needled, chemical bonded, coform and combinations thereof. 
     
     
       10. The hypochlorite-releasing substrate according to  claim 1 , wherein the substrate is substantially dry-to-the-touch. 
     
     
       11. The hypochlorite-releasing substrate according to  claim 1 , wherein the solid hypochlorite precipitate is 0.1 to about 10 times of the weight of the fibrous layer. 
     
     
       12. A hypochlorite-releasing substrate comprising:
 a) a first fibrous layer comprising fibers selected from the group consisting of: polypropylene, polyethylene, polyester and mixtures thereof; 
 b) a second fibrous layer; and 
 c) a solid hypochlorite precipitate, not in the form of particulates and which is formed around the fibers and in the interstices of the first fibrous layer, selected from the group consisting of: hypochlorite monohydrate salt, hypochlorite dihydrate salt, hemibasic hypochlorite salt, monobasie hypochlorite salt, dibasic hypochlorite salt, anhydrous hypochlorite salt, and mixtures thereof; 
 wherein the solid hypochlorite precipitate is evenly distributed throughout the first fibrous layer; and wherein the first fibrous layer which contains the hypochlorite precipitate is free of any glues, binders, or adhesives. 
 
     
     
       13. A hypochlorite-releasing substrate according to  claim 12 , wherein the substrate comprises at least three layers. 
     
     
       14. A hypochlorite-releasing substrate according to  claim 12 , wherein the substrate comprises said first fibrous layer, said second fibrous layer and a barrier material situated in between the first and second fibrous layers. 
     
     
       15. The hypochlorite-releasing substrate according to  claim 13 , further comprising an additive, loaded onto one of the fibrous layers, selected from the group consisting of: emulsifiers, pH adjusters, silicones, non-ionic surfactants, cationic surfactants, amphoteric surfactants, zwitterionic surfactants, anionic surfactants, soil release agents, soil release polymers, antistatic agents, fragrances, fragrance extenders, antimicrobial actives, preservatives, dyes, colorants, viscosity control agents, antifoaming agents, pearlizing agents, opacifying agents, antioxidants, sunscreens, dye transfer inhibitors, dye fixative agents, dispersants, chlorine scavengers, wetting agents, electrolytes, enzymes, brighteners, heavy metal chelating agents, fabric softener actives, soil suspending agents, and mixtures thereof. 
     
     
       16. A hypochlorite-releasing substrate comprising:
 a) a first fibrous layer; 
 b) a solid hypochlorite precipitate, not in the form of particulates, formed in the first fibrous layer that is selected from the group consisting of: hypochlorite monohydrate salt, hypochlorite dihydrate salt, hemibasic hypochlorite salt, monobasic hypochlorite salt, dibasic hypochlorite salt, anhydrous hypochlorite salt, and mixtures thereof; 
 c) a second fibrous layer; 
 d) at least one surfactant loaded onto the second fibrous layer; 
 wherein the solid hypochlorite precipitate is evenly distributed throughout the width of the first fibrous layer; and wherein the first fibrous layer which contains the hypochlorite precipitate is free of any glues, binders, or adhesives. 
 
     
     
       17. The hypochlorite-releasing substrate according to  claim 16 , wherein the substrate further comprises a cleaning composition loaded onto one or more of the fibrous layers. 
     
     
       18. The hypochlorite-releasing substrate according to  claim 16 , wherein the second fibrous layer comprises surfactants which form a solid surfactant precipitate. 
     
     
       19. The hypochlorite-releasing substrate according to  claim 16 , further comprising an additive, loaded onto one of the fibrous layers, selected from the group consisting of: emulsifiers, pH adjusters, silicones, non-ionic surfactants, cationic surfactants, amphoteric surfactants, zwitterionic surfactants, anionic surfactants, soil release agents, soil release polymers, antistatic agents, fragrances, fragrance extenders, antimicrobial actives, preservatives, dyes, colorants, viscosity control agents, antifoaming agents, pearlizing agents, opacifying agents, antioxidants, sunscreens, dye transfer inhibitors, dye fixative agents, dispersants, chlorine scavengers, wetting agents, electrolytes, enzymes, brighteners, heavy metal chelating agents, fabric softener actives, soil suspending agents, and mixtures thereof.